Box construction



March 27, 1962 s. L. BEDER BOX CONSTRUCTION 2 Sheets-Sheet 2 Filed Feb.26, 1960 FIG.3

FIG.4

INVENTOR. Samuel L. Beder Alma-W ATTORNEY United States atent 3,027,060BOX CONSTRUCTION Samuel L. Beder, Riverdale, N.Y., assignor to ToymasterProducts Co., Inc., Garfield, N.J., a corporation Filed Feb. 26, 196i),Ser. No. 11,244 1 Claim. (131. 229-116) This invention relates generallyto a box construction and method of making the same, and morespecifically to an open end, reinforced cardboard box and method ofmaking the same.

An object of this invention is to provide a sturdily constructed boxwhich is open at one end and a method of making the same in a relativelysimple and inexpensive manner utilizing a minimum number of componentsand operational steps.

Another object is to provide for making a reinforced, open end box ofdouble wall thickness which is particularly adapted for use as anamusement for children.

A feature of this invention resides in the provision that the reinforcedbox is formed primarily of only two component parts, and a covering ofornamental wrap.

The various features of novelty which characterize the invention arepointed out with particularity in the claims annexedto and forming apart of this specification. For a better understanding of the invention,its operating advantages and specific objects attained by its use,reference should be had to the accompanying drawings and descriptivematter in which there is illustrated and described a preferredembodiment of the invention.

In the drawings:

FIG. 1 is a plan view illustrating the inner surface of blank forforming the box in accordance with this invention.

FIG. 2 illustrates the outer surface of said blank with an ornamentedwrap sheet glued thereto.

FIG. 3 illustrates the inner surface of the blank of FIG. 2, depictingan intermediate step of the box forming operation wherein the continuousflap overlies the centerfold of the blank.

FIG. 4 illustrates the arrangement of FIG. 3 folded along the transversefold lines to define a four sided figure, with the bottom piece, shownin part, in position to square the sides of the box.

FIG. 5 is a detail view of the bottom piece.

FIG. 6 illustrates a perspective view of the box in almost completeform, having parts thereof broken away.

- FIG. 7 illustrates a perspective view of a nested set of boxes made inaccordance with this invention.

FIG. 8 is a schematic view of a roller press to facilitate gluing of theouter wrap to the blank.

Referring to the drawings, the open end box in accordance with thisinvention is constructed principally from a blank 10 which is arrangedto be folded in a predetermined fashion to form a reinforced, four-sidedbox closed at the bottom. An ornamental wrap or sheet is glued to theside panels of the box to give it an attractive appearance. In theparticular instance the ornamented wrap is illustrated with art workthat is appealing to small children. Preferably, the boxes in accordancewith this invention are made in various sizes so that they may be nestedone within the other to form a set of giant blocks to be utilized forthe particular amusement of children.

Referring to FIG. 1, the blank 10, formed preferably in a die cuttingmachine, is formed of a sturdy cardboard material, e.g. a corrugatedcardboard. As shown, the blank 10 is substantially rectangular in shapeand is provided with a pair of longitudinally extending fold lines 11and 12 to define a centerfold 13 and connected flaps 14, 15. Inaccordance with the illustrated embodiment flap 14 is continuous and itadjoins the lower edge of the centerfold 13 along fold line 12. Aplurality of slotted perforations 16 spaced at substantially equalintervals and extending normal to the fold line 12, divide thecontinuous flap 14. into four panels 14A, 14B, 14C and 14D. Fold line 17extends transversely of the centerfold 13 and divides it into fourpanels 13A, 13B, 13C and 13D, which have a width substantially equal tothe panels 14A-D of the continuous flap 14. Connected to each of thecenterfold panels 13A, B, C and D along fold line 11 are distinct flaps15A, 15B, 15C and 15D, respectively. It is to be noted that fold line 11has segments 11A and 11C which are spaced slightly above segments 11Band 11D thereof. Thus fold segments 11A, 11B, 11C and 11D faclitatealternate folding of opposed pairs of flaps 15A, 15B, 15C and 15D aswill be hereinafter described.

Connected to one end of the centerfold 13 is an end flap 18. Inaccordance with this invention the outer surface of the continuous flap14 is coated with a suitable dye or ink, to give it a solid color, suchas blue, or other suitable color. As will be hereinafter described, thiscolored surface of the flap 14 will form the inside visible surface ofthe box. The outer surface of the box will comprise an ornamental wrapsheet 19 which circumscribes the four sides of the box, and a bottomwrap 29 to cover the bottom of the box. Thus in accordance with thisinvention the box is formed essentially of blank 10 folded to form thefour sides of the box, a bottom piece 21 reinforced by flap 15, andornamental wrap sheets 19 and 20.

The method of constructing the box and folding of the blank 10 inaccordance with this invention is as follows:

The wrap sheet 19 which comprises a strip of paper printed on one sidewith attractive design, is coated on the other side thereof with a layerof glue. This wrap sheet 19 is sufficiently long to extend the length ofthe centerfold portion 13 of the blank 10. With the wrap sheet 19 coatedwith glue, it is placed in a suitable jig with the printed surface down.The die cut corrugated blank 10 is next placed in the jig on top of thewrap sheet 19 with the continuous flap 14 downward as viewed in FIG. 1.In this position the printed or colored surface of the continuous flap14 is face down. The blank It is positioned on the wrap 19 in a mannerso that the longitudinal edge of the wrap 19 overlies the fold lines 11and 12 about inch as viewed in FIG. 2, one end of the wrap 19 coincideswith the fold line 22 of the end flap 13 and the other end 19A of thewrap 19 extends beyond the opposite end of the centerfold about inch.

Pressure is then applied to adhere the wrap sheet 19 to the die cutblank 10. This is attained by passing the blank 10 and connected wrapsheet 19 through a roller press 23. As shown in FIG. 8, the blank 10 andconnected wrap sheet 19 are passed through rollers 23A and 23B with theblank 10 presented to the rollers along its longitudinal edge with thewrap 19 down. As shown, the upper roller 23A is somewhat shorter thanthat of the lower roller 23B. This is done to prevent the glue on theoverhang portion 19A of the wrap sheet 19 from. contacting any part ofthe upper roller 23A.

The blank 10 and attached wrap sheet 19 are then picked up manually byan operator and run through an edge gluer to coat the inside surface ofthe four panels or distinct flaps 15A, 15B, 15C and 15D with glue. Theblank 10 is then turned over and the outer surface of end flap 18 iscoated with glue.

The blank 10 and connected wrap 19 are now laid on a table with theprinted side of the continuous flap 14 down. The continuous flap 14 isthen folded to overlie the centerfold portion 13 of the blank 10. Inthis position, as shown in FIG. 3, the color side of the continuous flap14 is now in position to form the inner surface of the box.

The next operation is for the operator to fold the blank 10, as viewedin FIG. 3, inwardly along each of the transverse fold lines 17 to form afour-sided box, as seen in FIG. 4. The slotted opening 16 of thecontinuous flap 14 facilitates this operation. In this position the boXso formed is rested on a 45 jig (a wood form) and the end flap 18inserted between the inside panel 14A and the corresponding centerfoldportion or panel 13A. The end flap 13, previously coated with glue, issecured in position therebetween. The overhang 19A of the printed sheet19 is then folded down onto that wrap portion covering panel 13A tofinish the juncture corner.

The box is then taken off the 45 jig and placed by the operator on amandrel which has substantially the inside dimension of the box. In thespecific instance the mandrel is square. The operator then takes thebottom piece 21, which in this case is a square, as illustrated in FIG.5, and places it in the box. Preferably one side of the bottom piece 21is coated or printed with the same color ink as that of the continuousflap 14. The operator places the bottom piece within the box with itscolored side down. In this position the bottom piece 21 rests on theedge of the inturned continuous flap 14 and aids to keep the walls ofthe box squared.

With the box in this form the next step resides in bending inwardly thetwo opposed flaps 15B'and 15D so that the glue coated surface thereof isbrought to rest on the bottom piece 21 and adheres thereto. The othertwo opposed flaps 15A and 15C are next folded so that their glue coatedsurfaces rest on the outer side of closed flaps 15B and 15D. With theflaps down as seen in FIG. 6, a compressive force is applied to thebottom, the force being maintained until the glued flaps 15 are set. Theglue applied is of a type which requires no external heat and will setby pressure alone.

After the bottom flaps 15 have been set, the box is removed from themandrel. The bottom wrap 20 is then passed through a suitable gluingmachine so that the under side thereof is coated with glue. The bottomwrap 20 is then placed over the top of flaps 15A and 15C, the wrap beingsized so that its opposed edges 20A overlie the raw edges of the box.Thus the overhang portion 20A may be folded downwardly to finish off theopposite sides of the box. This completes the making of the box.

In accordance with this invention the box described may be made invarious sizes adapted to nest in one another as viewed in FIG. 7, toform a set of blocks. It is to be further noted that the boxes formed inaccordance with this invention constitute in fact a dobule wall boxwhich gives it the rigidity and sturdiness necessary to withstand theabuse of children and the box is sufiiciently strong to withstand theweight of a relatively large child, e.g. an average four year old.

While in accordance with the provisions of the statutes there isillustrated and described herein the best form and mode of operation ofthe invention now known to the inventor, those skilled in the art willunderstand that changes may be made in the form of the apparatusdisclosed without departing from the spirit of the invention covered bythe claims, and that certain features of the invention may sometimes beused to advantage without a corresponding use of other features.

What is claimed is:

A toy double walled play-box having an open end and a closed reinforcedbottom end comprising;

(a) a cardboard blank including a centerfold having longitudinal edgesand a plurality of spaced transversely extending foldlines to define aplurality of side panels disposed in side by side relationship,

(1)) a decorative wrap sheet secured to the outer side of saidcenterfold,

(c) a continuous flap connected along a longitudinal edge of saidcenterfold,

(:1) said continuous fiap having a spaced transversely extending slottedfoldlines to define a plurality of panels corresponding to the sidepanels defined by the foldlines of said centerfold, said slottedfoldlines of the continuous flap being disposed in alignment with thetransverse foldlines of said centerfold,

(e) said continuous flap being reversely folded degrees so as to overlaponto the inner surface of said centerfold,

(1) said continuous flap being proportioned with respect to thecenterfold so that in the folded position thereof the longitudinal endof said continuous flap falls short of the longitudinal edge of saidcenterfold opposite the foldline between the centerfold and theconnected continuous flap,

(g) an end flap connected to one end of said centerfold,

(h) said centerfold and connected reversely folded continuous flap beingbent along the corresponding transverse foldlines of said centerfold andcontinuous flap to define a closed figure,

(i) said end flap securing the ends of said closed figure at thejunction thereof,

(j) a separate and distinct bottom piece seated on the edge of saidreversely bent flap within the periphery of said closed figure asdefined by the centerfold,

(k) a distinct flap connected to each side panel of said centerfold,

(l) opposed pairs of said distinct flaps being alternately folded ontosaid bottom piece to close the bottom end of the box, and

(m) a bottom decorative wrap sheet secured to the closed bottom of thebox.

References Cited in the file of this patent UNITED STATES PATENTS850,490 Price Apr. 16, 1907 1,602,702 Pinkerton Oct. 12, 1926 1,845,456Wagner Feb. 16, 1932 1,997,909 Luce Apr. 16, 1935 2,110,782 Weber Mar.8, 1938 2,220,388 Beaman et al. Nov. 5, 1940 2,237,706 Islieb Apr. 8,1941 2,718,348 Montfort Sept. 20, 1955

